Electrical conductor aligning device and aligning method

ABSTRACT

An electrical conductor aligning device that can, without mutual interference, easily, and in a short period of time, align a plurality of electrical conductors in an annular shape while overlapping in the peripheral direction. The coil element aligning device includes: holding sections, a slide mechanism and a cylinder mechanism. One leg of each coil element is held by the plurality of holding sections, the plurality of coil elements being aligned in an annular shape at a spacing such that there is no overlapping in the peripheral direction, and then the plurality of holding sections being moved inwards in the radial direction by the slide mechanism and the cylinder mechanism, thereby aligning the plurality of coil elements in an annular shape while overlapping in the peripheral direction.

TECHNICAL FIELD

The present invention relates to an electrical conductor aligning deviceand an aligning method thereof. In detail, it relates to an electricalconductor aligning device that aligns a plurality of substantiallyU-shaped electrical conductors in an annular shape while overlapping inthe circumferential direction, and an aligning method thereof.

BACKGROUND ART

The stator coil of a rotating electrical machine is formed in thefollowing way, for example. First, a plurality of electrical conductorsmolded in a substantially U-shape are aligned in an annular shape whileoverlapping in the circumferential direction. Next, the legs of eachelectrical conductor aligned in an annular shape are inserted into therespective slots provided in an annular shape on the stator core. Then,the ends of adjacent legs are connected. The stator coil of a rotatingelectrical machine is thereby formed.

However, concerning technology for aligning a plurality of substantiallyU-shaped electrical conductors in an annular shape while overlapping inthe circumferential direction, a variety of considerations has been madethus far. For example, a technology has been proposed that inserts oneleg of a plurality of substantially U-shaped electrical conductors intoa plurality of housing grooves provided on an alignment ring pallet,respectively, and rotates the alignment ring pallet in this state (referto Patent Document 1). According to this technology, by the plurality ofelectrical conductors rotating by driving to follow the rotation of thealignment ring pallet, it is said that the plurality of electricalconductors can be aligned in an annular shape while overlapping in thecircumferential direction.

Patent Document 1: Japanese Unexamined Patent Application, PublicationNo. 2004-173357

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

However, with the technology of Patent Document 1, since the pluralityof electrical conductors are aligned in sequence while rotating thealignment ring pallet, time is required until the aligning of thesecompletes. In addition, when aligning in order while overlapping theplurality of substantially U-shaped electrical conductors in thecircumferential direction, upon aligning the last electrical conductor,interference occurs with the electrical conductors already aligned, andthus alignment becomes difficult.

The present invention has been made taking the above-mentioned problemsinto account, and an object thereof is to provide an electricalconductor aligning device and aligning method thereof that can align aplurality of electrical conductors in an annular shape while overlappingin the circumferential direction easily and in a short time, withoutinterference therebetween.

Means for Solving the Problems

In order to achieve the above-mentioned object, the present inventionprovides an electrical conductor aligning device (e.g., the aligningdevice 1 described later) that aligns a plurality of substantiallyU-shaped electrical conductors (e.g., the coil elements 10 describedlater) in an annular shape while overlapping in a circumferentialdirection, the device including: a plurality of holding sections (e.g.,the holding sections 5 described later) provided in an annular shapethat holds one leg of each of the electrical conductors; and a movingpart (e.g., the slide mechanisms 7, 7A and cylinder mechanism 9described later) that causes the plurality of holding sections to movein a radial direction, in which the plurality of electrical conductorsis aligned in an annular shape while overlapping in the circumferentialdirection, by aligning the plurality of electrical conductors in anannular shape at intervals not overlapping in the circumferentialdirection by way of the plurality of holding sections holding one leg ofeach of the electrical conductors, and then causing the plurality of theholding sections to move to an inner side in the radial direction by wayof the moving part.

With the present invention, one leg of each of the substantiallyU-shaped electrical conductor is held by the plurality of holdingsections provided in an annular shape, and thus the plurality ofelectrical conductors are made to be aligned in an annular shape atintervals so as not to overlap in the circumferential direction.Subsequently, by moving the plurality of holding sections to the innerside in the radial direction by way of the moving part, the plurality ofelectrical conductors are made to be aligned in an annular shape whileoverlapping in the circumferential direction.

The plurality of electrical conductors are thereby made to be arrangedin an annular shape spreading to a region not interfering with eachother, and from there, are made to move to the inner side in the radialdirection at almost the same time; therefore, the time required inaligning can be shortened. In addition, since each of the electricalconductors is made to be aligned by moving at almost the same time, itis possible to easily align the plurality of electrical conductorswithout interfering with each other, irrespective of the sequence ofalignment.

In this case, it is preferable for the plurality of holding sections tohave positions of adjacent holding sections arranged to be displaced ina central axis (e.g., the central axis X described later) direction ofthe annular shape.

In addition, with the present invention, the positions of adjacentholding sections are arranged to be displaced in the central axisdirection of the ring formed by the plurality of holding sections. It isthereby possible to avoid adjacent holding sections from interferingwhen causing the plurality of holding sections to move to the inner sidein the radial direction.

In addition, in this case, it is preferable for the plurality of holdingsections to have adjacent holding sections joined to each other by alink mechanism (e.g., the link mechanism 57 described later), and to becomprised of at least one first holding section (e.g., the first holdingsection 51 described later) that moves by receiving a direct drivingforce from the moving part and a plurality of second holding sections(e.g., the second holding sections 52 described later) that followmovement of the first holding section.

With the present invention, along with joining adjacent holding sectionsto each other by the link mechanism, the plurality of holding sectionsare configured by at least one of the first holding sections receivingthe direct driving force to move from the moving part, and a pluralityof the second holding sections that drive following the movement of thefirst holding section.

Since the adjacent holding sections are thereby joined by the linkmechanism, when the first holding section receives the direct drivingforce to move from the moving part, the second holding sections alsomove by following this. Therefore, in addition to being able to causethe plurality of holding sections to move almost at the same timeeasily, the device can be reduced in size, since it is not necessary toprovide drive sources to every holding section.

In addition, in this case, it is preferable for the plurality ofelectrical conductors to be comprised of a first electrical conductor(e.g., the first coil element 11 described later) and a secondelectrical conductor (e.g., the second coil element 12 described later)of a different shape from the first electrical conductor, and for theplurality of holding sections to respectively hold one leg of the firstelectrical conductor and one leg of the second electrical conductor.

With the present invention, along with using the first electricalconductor and second electrical conductor which differ in shape from oneanother as electrical conductors, one leg of the first electricalconductor and one leg of the second electrical conductor are defined asa group, and this is held by the respective holding sections.

Along with being able to more densely overlap the electrical conductorsby using two types of electrical conductors which differ in shape fromone another, by holding the one leg of each of the two types ofelectrical conductors by the respective holding sections as a group, itis thereby possible to reduce the number of holding sections compared toa case of providing a holding section for every electrical conductor. Asa result thereof, in addition to being able to avoid interferencebetween holding sections, and being able to align the electricalconductors in an annular shape reliably, the device can be reduced insize.

In addition, an electrical conductor aligning method of aligning aplurality of substantially U-shaped electrical conductors (e.g., thecoil elements 10 described later) in an annular shape while overlappingin a circumferential direction (e.g., the aligning method executed bythe aligning device 1 described later) is provided that includes: anarranging step of arranging the plurality of electrical conductors in anannular shape at an interval so as not to overlap in a circumferentialdirection, by holding one leg of each of the electrical conductors; andan aligning step of aligning the plurality of electrical conductors inan annular shape while overlapping in the circumferential direction, bycausing the plurality of electrical conductors arranged in the annularshape to move to an inner side in the radial direction.

The same effects as the above-mentioned invention of an aligning deviceare obtained according to the present invention.

Effects of the Invention

According to the present invention, it is possible to provide anelectrical conductor aligning device and aligning method thereof thatcan align a plurality of electrical conductors in an annular shape whileoverlapping in the circumferential direction easily and in a short time,without interference therebetween.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an aligning device according to a firstembodiment of the present invention;

FIG. 2 is a rear perspective view of a second holding section and slidemechanism according to the first embodiment;

FIG. 3 is front perspective view of a second upper holding section andslide mechanism according to the first embodiment;

FIG. 4 is a front perspective view of a second lower holding section andslide mechanism according to the first embodiment;

FIG. 5 is a rear perspective view of a first holding section and slidemechanism according to the first embodiment;

FIG. 6 is a partial cross-sectional plan view of a holding sectionaccording to the first embodiment;

FIG. 7 is a plan view of the aligning device according to the firstembodiment, and is a view showing a state when a plurality of holdingsections retract to separate to an outer side in the radial direction;

FIG. 8 is a side view of the aligning device according to the firstembodiment, and is a view showing a state when a plurality of holdingsections retracted to separate to an outer side in the radial direction;

FIG. 9 is a plan view of the aligning device according to the firstembodiment, and is a view showing a state when the plurality of holdingsections advance to meet at an inner side in the radial direction;

FIG. 10 is a side view of the aligning device according to the firstembodiment, and is a view showing a state when the plurality of holdingsections advance to meet at an inner side in the radial direction;

FIG. 11A is a view illustrating an aligning method of coil elements byway of the aligning device according to the first embodiment, and is aview showing a state in which coil elements are aligned in an annularshape at intervals so as not to overlap in the circumferentialdirection;

FIG. 11B is a view illustrating an aligning method of coil elements byway of the aligning device according to the first embodiment, and is aview showing a state in which coil elements are aligning in an annularshape while overlapping in the circumferential direction;

FIG. 12 is a perspective view of holding sections and a first coilelement and second coil element held by the holding sections accordingto a second embodiment of the present invention;

FIG. 13 is a view when looking at the holding section according to thesecond embodiment from an inner side in the radial direction;

FIG. 14A is a front perspective view showing the configurations of arotating part and flat part of the holding section according to thesecond embodiment;

FIG. 14B is a rear perspective view showing the configurations of therotating part and flat part of the holding section according to thesecond embodiment;

FIG. 15 is a plan view of the holding section according to the secondembodiment;

FIG. 16 is a perspective view of holding sections and first coilelements and second coil elements held by the holding sections accordingto a third embodiment of the present invention; and

FIG. 17 is a perspective view of the holding sections according to thethird embodiment of the present invention when the first coil elementsand second coil elements held by the holding sections are released.

EXPLANATION OF REFERENCE NUMERALS

-   1, 2, 3 aligning device-   5, 6, 8 holding section-   7, 7A slide mechanism (moving part)-   9 cylinder mechanism (moving part)-   10 coil element (electrical conductor)-   11 first coil element (first electrical conductor)-   12 second coil element (second electrical conductor)-   11A, 12A one lateral face-   11B, 12B other lateral face-   11C, 12C front face-   51 first holding section-   52 second holding section-   57 link mechanism-   631 first hook part (first lateral part)-   632 second hook part (second lateral part)-   633 rotating part-   634 flat part-   634A plane-   X central axis (central axis of ring)-   Y rotation axis

PREFERRED MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be explained indetail while referencing the drawings. It should be noted that, in theexplanation of a second embodiment, the same reference symbols areappended for configurations that are identical to a first embodiment,and explanations thereof are omitted. In addition, explanations areomitted also for the same operations and effects.

First Embodiment

An aligning device according to the first embodiment of the presentinvention aligns a plurality of substantially U-shaped coil elementsserving as the electrical conductors in an annular shape, whileoverlapping in the circumferential direction. Herein, the coil elementsfor rotating electrical machines that are respectively inserted intoeach slot of a stator core of a rotating electrical machine to form thestator coil by the ends of each other being connected are used as thecoil elements.

FIG. 1 is a perspective view showing an aligning device 1 according tothe first embodiment of the present invention. As shown in FIG. 1, thealigning device 1 includes a base 3, a plurality of holding sections 5,a plurality of slide mechanisms 7, 7A as movement parts, and twocylinder mechanisms 9, 9 as movement parts.

The base 3 supports the plurality of slide mechanisms 7, 7A describedlater. The base 3 includes four columnar base legs 31, and anannular-shaped flat part 33 supported by these base legs 31. Thediameter of a circular hole 35 in the center of the flat part 33corresponds to the diameter of the stator core of the rotatingelectrical machine, and is set to be somewhat larger than the diameterof the stator core, for example. With the aligning device 1 according tothe present embodiment, the stator core of the rotating electricalmachine that is not illustrated is arranged under the circular hole 35,and an insertion device that is not illustrated for inserting the coilelements aligned by the aligning device 1 into the respective slots ofthe stator core is arranged between the aligning device 1 and the statorcore. It thereby become possible to insert the legs of the plurality ofcoil elements aligned in an annular shape by the aligning device 1 intothe respective slots of the stator core by way of the insertion device.

The plurality of holding sections 5 hold a lower part of one leg of eachof the substantially U-shaped coil elements, which are not illustrated.As shown in FIG. 1, the plurality of holding sections 5 is arranged inan annular shape on the flat part 33 of the base 3. In more detail, theplurality of holding sections 5 is respectively supported by the slidemechanisms 7, 7A provided in a radial fashion on the flat part 33 of thebase 3, and are made movable in the radial direction by way of thedriving force of two cylinder mechanisms 9, 9.

In addition, as shown in FIG. 1, the plurality of holding sections 5 isarranged so that the positions of adjacent holding sections 5 arealternately displaced in the central axis X direction (height direction)of the ring. In more detail, the holding sections 5 are arranged to bealternately displaced in the central axis X direction so as not to beinterfering, when the plurality of holding sections 5 advances inwardsin the radial direction to meet by way of the slide mechanisms 7, 7Adescribed later.

The plurality of holding sections 5 are configured from two firstholding sections 51, 51 that move by receiving direct driving force fromthe cylinder mechanisms 9, 9 described later, and a plurality of secondholding sections 52 that follow the movement of the first holdingsections 51, 51. Herein, receiving direct driving force in the presentspecification indicates receiving the driving force of the cylindermechanisms 9, 9 not through the link mechanisms described later.

The two first holding sections 51, 51 are arranged to be opposing eachother, and are arranged to be displaced lower along the central axis Xdirection relative to an adjacent second holding section 52. Inaddition, the plurality of second holding sections 52 are configuredfrom a second upper holding section 53 arranged above, a second lowerholding section 55 arranged below, and these are alternately arranged inthe circumferential direction.

Among the plurality of holding sections 5, adjacent holding sections 5are joined to each other by an L-shaped link mechanism 57. The secondholding section 52 adjacent to the first holding section 51 is joined tothe first holding section 51 by way of this link mechanism 57, and thesecond holding section 52 joined to this first holding section 51 isjoined to an adjacent second holding section 52. By the adjacent secondholding sections being sequentially joined in this way, the plurality ofsecond holding sections 52 follow the movement of the first holdingsection 51. The link mechanism 57 will be described in detail at a laterstage.

FIG. 2 is a rear perspective view of the second holding section 52 andslide mechanism 7 according to the present embodiment. In more detail,FIG. 2 shows the second upper holding section 53 and second lowerholding section 55 arranged alternately, and four of the slidemechanisms 7 supporting these holding sections.

As shown in FIG. 2, each of the slide mechanisms 7 is mounted on theflat part 33 of the base 3, and includes a slide rail 71 that extends inthe radial direction, a slide guide 73 that engages with the slide rail71, and a guide plate 75 that is mounted to the slide guide 73 andextends in the radial direction along the slide rail 71. The secondupper holding section 53 and second lower holding section 55 are led tothe slide guide 73 and guide plate 75 engaging with the slide rail 71and moving on the slide rail 71, and thus become movable in the radialdirection.

The second upper holding section 53 and second lower holding section 55are both supported by the slide guide 73 via a plate-shaped connectionpart 4 that is mounted on the top surface of the slide guide 73,respectively, and extends inwards in the radial direction. Theconnection part 4 is not at the center in the circumferential directionof each holding section, but is joined to one side (right side in FIG.2), whereby it becomes possible to make the plurality of holdingsections 5 to tightly meet.

In addition, the second upper holding section 53 is joined with oneadjacent second lower holding section 55 by the link mechanism 57mounted on the top surface of the connection part 4. At the same time,it is joined to the other adjacent second lower holding section 55 byway of the link mechanism 57 mounted on the bottom surface of theconnection part 4.

As shown in FIG. 2, the link mechanism 57 is configured from an L-shapedplate member consisting of a short part 571 and a long part 573 in whichan elongated hole 575 is formed; and a bolt 570. In this link mechanism57, the short part 571 is fixed to one connection part 4. The elongatedhole 575 formed in the long part 573 is formed in a width smaller thanthe diameter of the head of the bolt 570 and slightly larger than thediameter of the shank of the bolt 570. The shank of the bolt 570 isinserted in this elongated hole 575, and the bolt 570 is fixed to theother connection part 4 in a state in which a space is ensured betweenthe long part 573 and the head of the bolt 570. Movement of the bolt 570in the width direction inside of the elongated hole 575 is therebyregulated, while movement of the bolt 570 in the length direction insideof the elongated hole 570 is permitted. For this reason, the pluralityof holding sections 5 become moveable in the radial direction, byfollowing the movement in the radial direction of adjacent holdingsections 5.

FIG. 3 is a front perspective view of the second upper holding section53 and slide mechanism 7 according to the present embodiment. Inaddition, FIG. 4 is a front perspective view of the second lower holdingsection 55 and slide mechanism 7 according to the present embodiment. Asshown in this FIG. 3 and FIG. 4, the second upper holding section 53 ismounted to a top surface 41 side of the connection part 4; whereas, thesecond lower holding section 55 is mounted to a bottom face 43 side ofthe connection part 4. The position in the central axis X direction ofthe second upper holding section 53 and the position in the central axisX direction of the second lower holding section 55 thereby becomedifferent positions.

FIG. 5 is a rear perspective view of the first holding section 51 andslide mechanism 7A according to the present embodiment. As shown in FIG.5, the first holding section 51 is the same configuration as theaforementioned second lower holding section 55, and is mounted to thebottom face 43 side of the connection part 4.

The slide mechanism 7A supporting the first holding section 51 isbasically the same configuration as the aforementioned slide mechanism7, and includes the slide rail 71, slide guide 73 and guide plate 75.

However, different from the slide mechanism 7, the slide mechanism 7Afurther includes a gripped part 45 that is gripped by a gripping partprovided to a leading end of a rod of the cylinder mechanism 9 describedlater. The gripped part 45 is provided to project above the top surfaceof the connection part 4, and is gripped by fitting into a convex partof the gripping part of the cylinder mechanism 9. The driving force ofthe cylinder mechanism 9 is thereby transmitted to the slide mechanism7A supporting the first holding section 51 via the gripped part 45.

In addition, the slide mechanism 7A includes an outside stopper 715 thatregulates the movement outwards in the radial direction of the slideguide 73 supporting the first holding section 51. The outside stopper715 is run in a direction substantially perpendicular to the radialdirection, and is fixed on the flat part 33 of the base 3 by a fixingmember 717. By this outside stopper 715 abutting the slide guide 73, themovement outwards in the radial direction of the slide guide 73supporting the first holding section 51 is regulated.

In addition, the slide mechanism 7A includes an inside stopper 713 thatregulates the movement inwards in the radial direction of the slid guide73 supporting the first holding section 51. The inside stopper 713 isrun from the bottom surface of the horizontal section 711 is rundownwards from the bottom surface of a horizontal part 711 running fromthe slide guide 73 towards outside in the radiation direction, and abutsfrom the outer side in the radial direction an inside stopper bolt 331provided on the flat part 33 of the base 3, whereby the movement inwardsin the radial direction of the slide guide 73 supporting the firstholding section 51 is regulated.

FIG. 6 is a partial cross-sectional plan view of a holding section 5according to the present embodiment. Herein, for the first holdingsection 51, second upper holding section 53 and second lower holdingsection 55 constituting the plurality of holding sections 5, the basicconfigurations thereof are the same as aforementioned, and only differin being mounted on the upper side or being mounted on the lower side ofthe connection part 4. Therefore, FIG. 6 shows by giving the secondupper holding section 53 as an example, and the configuration of theholding section 5 will be explained in detail by referencing FIG. 6.

As shown in FIG. 6, the second upper holding section 53 includes aholding section main body 530 mounted to the connection part 4, and apair of hook parts 533, 533 mounted to a leading end side of the holdingsection main body 530.

In the holding section main body 530, two concave parts 531, 531 whichare indented to a base end side, and a projecting part 532 that projectsto a leading end side between these concave parts 531, 531 are formed.

Each of the hook parts 533 is mounted to the holding section main body530 in a state in which the base end side is inserted inside therespective concave parts 531. Each of the hook parts 533 extends by theleading end side spreading, and forms a substantially U-shape with theprojecting part 532 provided between the two concave parts 531, 531 ofthe holding section main body 530, thereby making it possible to insertone leg of the coil element between these.

Each of the hook parts 533 grips one leg of the coil element between theleading end side thereof and the projecting part 532 by way of a pair ofchuck mechanisms 534, 534 provided on both side faces of the holdingsection main body 530. In more detail, one leg of one coil element isgripped between one hook part 533 and the projecting part 532, and oneleg of another coil element adjacent to the one coil element is grippedbetween the other hook part 533 and the projecting part 532. It shouldbe noted that one leg of each coil element is held by configuring sothat the other leg of each coil element is not held, and the other legnot held is position more inwards in the radial direction than the oneleg that is held.

Each chuck mechanism 534 includes an insertion part 535 and a spring536. The insertion part 535 has a head on a base end side fixed by abolt 537 to a lateral face of the holding section main body 530, and theleading end side of the shank penetrates through the base end side ofthe respective hook parts 533 to be inserted to inside of the projectingpart 532. Each insertion part 535 is inserted until the leading endsabut each other. The spring 536 is coiled in a state compressed at theshank of each insertion part 535.

The second upper holding section 53 including the above configurationinserts the leg of the coil element while sliding, between the leadingend side of each hook part 533 and the projecting part 532. When this isdone, the base end side of each hook part 533 is pushed to spreadoutwards. At this time, the base end side of each hook part 533 ispressed to the side of the projecting part 532 by way of the strongbiasing force of the spring 536. The leg of the coil element is therebygripped by the force to the side of the projecting part 532 beingimparted to the leading end side of each hook part 533.

Referring back to FIG. 1, the two cylinder mechanisms 9, 9 respectivelyimpart a direct driving force on the first holding sections 51 asaforementioned. As shown in FIG. 1, the two cylinder mechanisms 9, 9 arearranged opposite via the base 3. Each of the cylinder mechanisms 9includes a support base 90, a cylindrical cylinder 91 supported by thesupport base 90, a piston that is not illustrated, provided to be ableto reciprocate inside of the cylinder 91, a rod 93 connected to thepiston, and a gripping part 95 provided at the leading end of the rod93.

To each of the gripping parts 95, a concave part 951 indented upwards isformed in the lower surface side thereof, and each of the concave parts951 fits to the aforementioned gripped parts 45 that project, wherebythe gripped part 45 is gripped by the gripping part 95. The drivingforce of each of the cylinder mechanisms 9 is thereby transmitted to theslide mechanism 7A supporting the first holding section 51.

By the aligning device 1 according to the present embodiment includingthe above configuration operating, execution of the aligning methodaccording to the present invention becomes possible. Operation of thealigning device 1 according to the present embodiment will be explainedwhile referencing FIGS. 7 to 11A and 11B.

Herein, FIGS. 7 and 9 are plan views of the aligning device 1 accordingto the present embodiment, and FIGS. 8 and 10 are side views of thealigning device 1 according to the present embodiment. FIGS. 7 and 8 areviews showing a state when a plurality of holding sections 5 retract toseparate to an outer side in the radial direction, and FIGS. 9 and 10are views showing a state when the plurality of holding sections 5advance to meet at an inner side in the radial direction. In addition,FIG. 11A is a view illustrating the aligning method of the coil elements10 by way of the aligning device 1 according to the present embodiment,and is a view showing a state in which the coil elements 10 are alignedin an annular shape at intervals so as not to overlap in thecircumferential direction. In addition, FIG. 11B is a view illustratingthe aligning method of the coil elements 10 by way of the aligningdevice 1 according to the present embodiment, and is a view showing astate in which the coil elements 10 are aligning in an annular shapewhile overlapping in the circumferential direction.

It should be noted that the plan views of FIGS. 7 and 9 omitillustration of the coil elements held by the holding sections 5 as amatter of convenience, and the side views of FIGS. 8 and 10 omit theillustration of parts of the coil elements and holding sections as amatter of convenience. In addition, FIGS. 11A and 11B illustratetogether with the stator core 15, which is arranged below the circularhole 35.

First, as shown in FIGS. 7 and 8, the two cylinder mechanisms 9, 9 aredriven to retract the first holding sections 51 to an outer side in theradial direction by way of the slide mechanism 7A, until the outsidestopper 715 abuts the slide guide 73. When this is done, the secondholding sections 52 also follow the movement of the first holdingsections 51 by way of the plurality of link mechanisms 57 and slidemechanisms 7 to retract to the outer side in the radial direction. Theentirety of the plurality of holding sections 5 thereby enters a stateretracted to separate to the outer side in the radial direction.

Next, in this state, the lower part of one leg of each coil element 10is gripped and held by the respective holding sections 5. As shown inFIG. 11A, the plurality of coil elements 10 are thereby arranged in anannular shape at intervals not overlapping in the circumferentialdirection. It should be noted that, at this time, the other leg of eachof the coil elements 10 is not gripped, and one leg of each of the coilelements 10 is gripped by configuring so that the other leg not beinggripped is positioned more inwards in the radial direction than the oneleg that is gripped.

Herein, the plurality of coil elements 10 used in the present embodimentconsists of one type of coil element, and more specifically, is asubstantially U-shaped coil element like that shown in FIG. 8. This coilelement 10, for example, is molded by carrying out the following. First,four linear rectangular wires for the coil are made into a bundle, andat substantially the central part thereof, an S-shaped part that assumesa substantially S-shape is molded on a first plane. Next, both legs moreto the end sides than the S-shaped part are bent in directionsapproaching each other. Next, along a second plane that is substantiallyorthogonal to the first plane, the substantially central part of theS-shaped part is curved while twisting, thereby molding into a mountainshape in which the S-shaped part is made into a substantially summitportion. The substantially U-shaped coil element 10 is thereby obtained.

The coil element 10 obtained in this way is twisted during molding,along with a cross section of the leg being a rectangular shape. Forthis reason, by gripping one leg between the hook part 533 andprojecting part 532 of a U-shape, by configuring so that lateral facesof one leg abut the hook part 533 and projecting part 532, the other legthat is not gripped is automatically arranged more to an inner side inthe radial direction than the one leg that is gripped.

Next, as shown in FIGS. 9 and 10, the cylinder mechanisms 9, 9 are madeto drive to advance the first holding section 10 to an inner side in theradial direction by way of the slide mechanism 7, until the insidestopper 713 abuts the inside stopper bolt 331. When this is done, thesecond holding section 52 also follows the movement of the first holdingsection 51 by way of the plurality of link mechanisms 57 and slidemechanism 7, to advance to the inner side in the radial direction. Theentirety of the plurality of holding sections 5 thereby enters a stateadvanced to meet at the inner side in the radial direction.

At this time, the plurality of coil elements 10 having one leg grippedby the respective holding sections 5 advances to the inner side in theradial direction at almost the same time, as show in FIG. 11B, therebymeeting while overlapping each other in the circumferential direction(corresponding to aligning step of the aligning method according to thepresent invention). From the above, the plurality of coil elements 10aligns in an annular shape while overlapping in the circumferentialdirection.

It should be noted that, as shown in FIG. 9, the diameter of the ring ofcoil elements 10 aligned in an annular shape is set to be smaller thanthe diameter of the circular hole 35 formed in the flat part 33 of thebase 3. The legs of the coil elements 10 aligned in an annular shapethereby come to be easily inserted into the slots of the stator core 15arranged below the circular hole 35.

The following effects are exerted according to the aligning device 1according to the present embodiment.

First, with the present embodiment, one leg of each of the substantiallyU-shaped coil elements 10 is held by the plurality of holding sections 5provided in an annular shape, and thus the plurality of coil elements 10are made to be aligned in an annular shape at intervals so as not tooverlap in the circumferential direction. Subsequently, by moving theplurality of holding sections 5 to the inner side in the radialdirection by way of the slide mechanisms 7, 7A and cylinder mechanism 9,the plurality of coil elements 10 are made to be aligned in an annularshape while overlapping in the circumferential direction.

The plurality of coil elements 10 are thereby made to be arranged in anannular shape spreading to a region not interfering with each other, andfrom there, are made to move to the inner side in the radial directionat almost the same time; therefore, the time required in aligning can beshortened. In addition, since each of the coil elements 10 is made to bealigned by moving at almost the same time, it is possible to easilyalign the plurality of coil elements 10 without interfering with eachother, irrespective of the sequence of alignment.

In addition, with the present embodiment, the positions of adjacentholding sections 5 are arranged to be displaced in the central axis Xdirection of the ring formed by the plurality of holding sections 5. Itis thereby possible to avoid adjacent holding sections 5 frominterfering when causing the plurality of holding sections 5 to move tothe inner side in the radial direction.

In addition, with the present embodiment, along with joining adjacentholding sections 5 to each other by the link mechanisms 57, theplurality of holding sections 5 are configured by at least one of thefirst holding sections 51 receiving the direct driving force to movefrom the cylinder mechanism 9, and a plurality of the second holdingsections 52 that drive following the movement of the first holdingsection 51.

Since the adjacent holding sections 5 are thereby joined by the linkmechanisms 57, when the first holding section 51 receives the directdriving force to move from the cylinder mechanism 9, the second holdingsections 52 also move by following this. Therefore, in addition to beingable to cause the plurality of holding sections 5 to move almost at thesame time easily, the device can be reduced in size, since it is notnecessary to provide drive sources to every holding section 5.

In addition, similar effects as the aforementioned effects are exertedaccording to the aligning method executed by the aligning device 1according to the present embodiment.

Second Embodiment

An aligning device 2 according to a second embodiment of the presentinvention is the same configuration as the aligning device 1 accordingto the aforementioned first embodiment, except for the point in that theconfigurations of the holding sections and connection part differ. Inaddition, although one type of the coil elements 10 are aligned in anannular shape in the first embodiment, the two types of the first coilelement and second coil element, which differ in shape from one another,are aligned in an annular shape by the aligning device 2 according tothe present embodiment.

Hereinafter, the configuration of the holding section of the aligningdevice 2 according to the present embodiment will be explained in detailwhile referencing FIGS. 12 to 15.

FIG. 12 is a perspective view of holding sections 6 of the aligningdevice 2 and a first coil element 11 and second coil element 12 held bythe holding sections 6 according to the present embodiment. In moredetail, FIG. 12 is a perspective view of the first coil elements 11 andsecond coil elements 12 held by the second upper holding sections 63 andsecond lower holding sections 65 constituting the plurality of holdingsections 6.

As shown in FIG. 12, the holding sections 6 are integrally molded to theleading end side of the connection part 40. In addition, the basicconfigurations of the first holding section 61 (not illustrated), secondupper holding section 63 and second lower holding section 65constituting the plurality of holding sections 6 are the same, and thepoint of only differing in being mounted to an upper side or mounted toa lower side of the connection part 4 is the same as the firstembodiment. More specifically, the first holding section 61 and thesecond lower holding section 65 are mounted to the lower side of theconnection part 4, and the second upper holding section 63 is mounted tothe upper side of the connection part 4. Therefore, FIGS. 12 to 15 areillustrated giving the second upper holding section 63 as an example,and the configuration of the holding section 6 will be explained indetail by referencing FIGS. 12 to 15.

Herein, the first coil element 11 and second coil element 12 both aresubstantially U-shaped coil elements molded in a mountain shape in whichthe S-shaped part is a substantially summit portion, by curving whiletwisting the substantially central part of the S-shaped part, similarlyto the aforementioned coil element 10. However, the second coil element12 is a U shape that is smaller than the first coil element 11, and ismolded so that the second coil element 12 fits together in the innercircumference of the first coil element 11.

As shown in FIG. 12, the aligning device 2 according to the presentembodiment is made with one leg of the first coil element 11 and one legof the second coil element 12 as a group, and holds this with each ofthe holding sections 6. More densely aligning the first coil element 11and second coil element 12 alternately in the circumferential directionthereby becomes possible.

The second upper holding section 63 includes a holding section main body630 mounted to the connection part 4, and a first hook part 631 andsecond hook part 632 serving as a first lateral part and second lateralpart provided to a leading end side of the holding section main body630.

The holding section main body 630 is formed so as to become graduallywider in width at one end side from the base end side towards a leadingend side. The first hook part 631 and second hook part 632 areintegrally molded at both end sides of the leading end face of theholding section main body 630, and the holding section main body 630,first hook part 631 and second hook part 632 are an integratedstructure.

The first hook part 631 and second hook part 632 are respectively formedin a substantially L shape in a plan view, and are provided so that theinner faces of each oppose each other. Each hook part has a short partintegrally molded at one end side of the leading end face of the holdingsection main body 630, and a long part that is provided to extend to aleading end side.

During operation as shown in FIG. 12, one lateral face 11A of one leg ofthe first coil element 11 abuts an inner face 631A of the first hookpart 631 serving as a first lateral part. Similarly, a lateral face 12Aof one leg of the second coil element 12 abuts an inner face 632A of thesecond hook part 632 serving as a second lateral part.

In addition, the second upper holding section 63 includes a rotatingpart 633 and flat part 634 at a central part of a leading end face ofthe holding section main body 630, as a chuck mechanism.

FIG. 13 is a view looking at the holding section 6 of the aligningdevice 2 from the inner side in the radial direction. FIG. 14A is afront perspective view showing the configurations of the rotating part633 and flat part 634 of the holding section 6 of the aligning device 2.FIG. 14B is a rear perspective view showing the configurations of therotating part 633 and flat part 634 of the holding section 6 of thealigning device 2.

As shown in FIGS. 13, 14A and 14B, the rotating part 633 is integrallyformed with a motor 636 described later and a housing 637 in which theoutput shaft thereof (rotation axis Y) is inserted. The rotating part633 thereby becomes rotatable between the first hook part 631 and secondhook part 632, about the rotation axis Y, which is substantiallyparallel with these hook parts. During operation, the rotating part 633abuts another lateral face 11B of the one leg of the first coil element11, and another lateral face 12B of the one leg of the second coilelement 12.

The rotating part 633 is formed in an elliptical column shape theextends in the direction of the rotation axis Y. The minor axis of therotating part 633 is set so that a space on an order that the one leg ofeach coil element is insertable between the rotating part 633 and theinner face of each hook part is ensured when the major axis direction ofthe rotating part 633 is made a substantially vertical direction.

In addition, the rotating part 633 is made so that the diameter thereofbecomes somewhat smaller towards the leading end side (flat part 634side).

Therefore, by defining the major axis direction of the rotating part 633as a substantially vertical direction, a sufficient space for insertingone leg of the first coil element 11 between the first hook part 631 andthe rotating part 633 is ensured. Similarly, a sufficient space forinserting one leg of the second coil element 12 between the second hookpart 632 and rotating part 633 is ensured.

On the other hand, by causing the rotating part 633 to undergopredetermined angle rotation from this state (Both clockwise andcounter-clockwise are possible, for example, rotation so that theorientation of the flat part 634 becomes about 38 degrees from thehorizontal direction. The same applies hereinafter.), the space betweenthe first hook part 631 and rotating part 633 is sufficiently narrowed,and the one leg of the first coil element 11 is gripped between these.Similarly, the space between the second hook part 632 and rotating part633 is sufficiently narrowed, and the one leg of the second coil element12 is gripped between these.

It should be noted that the rotational action of the plurality ofrotating parts 633 is cyclically controlled by controlling a pluralityof the motors 636 by way of a controller that is not illustrated.

The flat part 634 is provided to a leading end of the rotating part 633,and extends a predetermined length from the rotating part 633 to bothouter sides in the major axis direction thereof. In other words, theflat part 634 is joined with the rotating part 633 at the central partthereof.

In addition, a plane 634A on the rotating part 633 side of the flat part634 is formed in a tapered shape sloping to the rotating part 633 fromthe outer side towards the inner side. In other words, the flat part 634is formed so that the thickness thereof becomes thinner to the outerside. The flat part 634 thereby rotates along with the rotating part633, and the tapered plane 634A abuts a front face 11C of the one leg ofthe first coil element 11 and a front face 12C of the one leg of thesecond coil element 12 to press the these front faces, whereby each coilelement is pushed more to an interior side of each hook part, and ismore strongly gripped.

It should be noted that the extending length of the flat part 634 is seton an order so that, when the rotating part 633 rotates theaforementioned predetermined angle, the tapered plane 634A abuts thefront face 11C of the one leg of the first coil element 11 and the frontface 12C of the one leg of the second coil element 12, and cansufficiently press these front faces.

It should be noted that, as shown in FIG. 13, in an inner face 631A ofthe first hook part 631 and an inner face 632A of the second hook part632, concave parts indented towards the outside are formed, andanti-skid urethane rubber 631B, 632B is mounted to the concave partsthereof. It thereby becomes possible to more reliably grip and hold oneleg of each of the first coil element 11 and second coil element 12.

FIG. 15 is a plan view of the holding section 6 of the aligning device2. In more detail, it is a plan view showing a state when one leg of thefirst coil element 11 and one leg of the second coil element 12 aregripped by causing the rotating part 633 to undergo predetermined anglerotation from a state setting the major axis direction of the rotatingpart 633 as a substantially vertical direction.

As shown in FIG. 15, within the central part of the holding section mainbody 630, the motor 636 and the housing 637 in which the output shaft(rotation axis Y) of the motor 636 is inserted are provided. Inaddition, within both side parts of the holding section main body 630,fixing parts 638, 638 that fix the output shaft by fixing the housing637 from the side are provided. The rotating part 633 and flat part 634rotate about the rotation axis Y by way of driving of the motor 636.

The operation of the aligning device 2 according to the presentembodiment is the same as the aligning device 1 according to the firstembodiment, except for the operation of the holding section 6.

The holding section 6 according to the present embodiment grips andholds one leg of each of the first coil element 11 and second coilelement 12 by operating as follows.

First, in a state in which the entirety of the plurality of holdingsections 6 retracts to separate to the outer side in the radialdirection, the motor 636 is made to drive to make the rotating part 633rotate so that the major axis of the rotating 633 becomes asubstantially vertical direction. A sufficient space for inserting oneleg of the first coil element 11 between the first hook part 631 androtating part 633 is thereby ensured. Similarly, a sufficient space forinserting one leg of the second coil element 12 between the second hookpart 632 and rotating part 633 is ensured. In addition, at this time,the extending direction of the flat part 634 similarly becomes asubstantially vertical direction.

Next, the one leg of the first coil element 11 is inserted between thefirst hook part 631 and rotating part 633. In addition, the one leg ofthe second coil element 12 is inserted between the second hook part 632and rotating part 633.

After insertion, the rotating part 633 is made to undergo predeterminedangle rotation by driving the motor 636. The space between the firsthook part 631 and rotating part 633 is thereby sufficiently narrowed,whereby the one leg of the first coil element 11 is gripped betweenthese. Similarly, the space between the second hook part 632 androtating part 633 is sufficiently narrowed, whereby the one leg of thesecond coil element 12 is gripped between these.

In addition, at this time, the flat part 634 also rotates along with therotating part 633, and abuts the front face 11C of the one leg of thefirst coil element 11 and the front face 12C of the one leg of thesecond coil element 12 from outside portions of the tapered plane 634A,and the inside portion abuts these front faces to press these frontfaces more as rotation progresses. Each coil element is thereby pushedmore into the interior, and more strongly gripped.

It should be noted that, after aligning each of the coil elements in anannular shape, upon inserting the legs of each of the coil elements intothe respective slots of the stator core 15 arranged below the circularhole 35, the motor 636 is made to drive to cause the rotating part 633to rotate so that the major axis direction of the rotating part 633becomes a substantially vertical direction. By the space between thesecond hook part 632 and rotating part 633 being sufficiently spreadalong with the space between the first hook part 631 and rotating part633 being sufficiently spread, the one leg of each of the first coilelement 11 and second coil element 12 being gripped are therebyreleased.

In addition to the effects of the aligning device 1 according to thefirst embodiment, the following effects are exerted by the aligningdevice 2 according to the present embodiment.

With the present embodiment, along with using the first coil element 11and second coil element 12 which differ in shape from one another aselectrical conductors, one leg of the first coil element 11 and one legof the second coil element 12 are defined as a group, and this is heldby the respective holding sections 6.

Along with being able to more densely overlap the coil elements by usingtwo types of coil elements which differ in shape from one another, byholding the one leg of each of the two types of coil elements by therespective holding sections 6 as a group, it is thereby possible toreduce the number of holding sections 6 compared to a case of providinga holding section for every coil element. As a result thereof, inaddition to being able to avoid interference between holding sections 6,and being able to align the coil elements in an annular shape reliably,the device can be reduced in size.

However, for example, in the case of holding by sandwiching the leg of acoil element from two directions by way of the biasing force of aspring, in addition to not being able to release as a matter of course,it is necessary to insert and slide the leg between the sandwichingfaces upon sandwiching. For this reason, in the case of using coilelements made by bundling a plurality of elastic bodies having a largecoefficient of friction, there is risk of the shape variation of coilelements not being able to be compensated, and thus not being able toreliably hold.

In addition, when trying to pinch the leg of a coil element from fourdirections, for example, it is necessary to provide a separate drivemechanism, and thus the holding sections increase in size. In this case,holding sections interfere with each other upon aligning, and thus it isnot possible to align the electrical conductors. Furthermore, whentrying to release, an open/close mechanism by a drive source becomesespecially necessary, and thus the holding section increases in size.

In contrast, with the present embodiment, along with providing to theholding section 6 the first hook part 631 that abuts one lateral face11A of one leg of the first coil element 11 and the second hook part 632that abuts one lateral face 12A of one leg of the second coil element12, the rotating part 633 that is rotatable about the rotation axis Ywhich is substantially parallel to these hook parts, and abuts the otherlateral face 11B of the one leg of the first coil element 11 and theother lateral face 12B of the one leg of the second coil element 12 isprovided to the holding section 6 between these hook parts. In addition,this rotating part 633 is formed in an elliptical columnar shape thatextends in the rotation axis Y direction.

It is thereby possible to change the space between the rotating part 633and the first hook part 631 and the space between the rotating part 633and the second hook part 632 by the elliptical column-shaped rotatingpart 633 rotating, whereby holding and releasing the legs of therespective coil elements is possible. In more detail, since thereduction and expansion of these spaces is possible simultaneously, theleg of the first coil element 11 and the leg of the second coil element12 can be held and released simultaneously. Therefore, according to thepresent embodiment, along with being able to reliably hold a coilelement with a strong force by way of a simple structure, this can bereleased thereby. In addition, the holding sections 6 can be reduced insize, and thus the aligning device 2 can be reduced in size.

In addition, with the present embodiment, the flat part 634 that extendsfrom the rotating part 633 to both outer sides in the major axisdirection thereof is provided to the leading end of the rotating part633. In addition, the plane 634A on the rotating part 633 side of theflat part 634 is formed in a tapered shape so as to slope to therotating part 633 side from the outer side towards the inner side.

When the flat part 634 rotates along with the rotating part 633, itthereby abuts the front face of each of the coil elements from anoutside portion of the plane 634A on the rotating part 633 side of theflat part 634, and the inside portion abuts the front face of each ofthe coil elements more as rotation progresses. At this time, since theplane 634A on the rotating part 633 side of the flat part 634 is formedin a tapered shaped so as to slope to the rotating part 633 side fromthe outer side towards the inner side, it is possible to push each coilelement more to the interior of the concave part by pressing the frontface of each of the coil elements, and thus each of the coil elementscan be held more strongly. Consequently, displacement of the holdingpositions of the coil elements can be adjusted.

Third Embodiment

An aligning device 30 according to a third embodiment of the presentinvention is the same configuration as the second embodiment, except forthe configuration of the holding sections differing from the secondembodiment. Herein, FIG. 16 is a perspective view of a holding section 8and the first coil element 11 and second coil element 12 held by theholding section 8 according to the third embodiment. In addition, FIG.17 is a perspective view of the holding section 8 according to the thirdembodiment when the first coil element 11 and second coil element 12held by the holding section 8 are released.

As shown in FIGS. 16 and 17, the holding section 8 of the aligningdevice 30 according to the present embodiment corresponds to a part inwhich two of the holding sections 6 of the second embodiment areprovided vertically in two stages to the respective slide mechanisms 7,7A. The holding sections 6, 6 provided vertically in two stages areintegrally molded with the respective connection parts 40, 40, and thebase end sides of these connection parts 40, 40 are connected via anintermediate member 400. With the present embodiment, it thereby becomespossible to hold the legs of coil elements stably since the legs aregripped by the vertical two stages of holding sections 6, 6.

In addition, the vertical two-stages of holding sections 6, 6 arerespectively arranged to mutually match with adjacent verticaltwo-stages of holding sections 6, 6 in the horizontal direction. Herein,since the width dimension is relatively large with the holding section 5of the first embodiment, it is necessary to arrange the second upperholding section 53 and second lower holding section 55 to be alternatelydisplaced in the height direction in order to avoid interference betweenadjacent hook parts. In contrast, since the width dimension is smallwith the holding section 6 of the second embodiment, it becomes possibleto arrange the vertical two-stage holding sections 6, 6 to mutuallymatch with adjacent vertical two-stage holding sections 6, 6 in thehorizontal direction, as in the present embodiment.

It should be noted that, as shown in FIG. 17, the flat parts 634, 634provided in the vertical two stages are extended at a length so thatthere is no mutual interfering when the orientation of each flat part(extending direction) is set to a substantially vertical direction.Holding and releasing of the coil elements thereby becomes possible in astate in which the plurality of holding sections 8 meets.

The aligning device 30 according to the present embodiment operatessimilarly to the aligning device 2 according to the second embodiment,and thus the same effects are exerted thereby.

It should be noted that the present invention is not to be limited tothe above-mentioned embodiments, and modifications and improvements of ascope that can achieve the objects of the present invention areencompassed by the present invention.

For example, with the above-mentioned embodiments, coil elements for arotating electric machine are employed as the electrical conductors;however, it is not limited thereto, and may be any electrical conductormolded in a substantially U-shape.

In addition, although the one type of the coil element 10 is used in thefirst embodiment, and the two types of the first coil element 11 andsecond coil element 12 are used in the second embodiment, it is notlimited thereto. For example, these coil elements can be employed in anyof the embodiments, and it is possible to employ more types of coilelements in any of the embodiments.

In addition, although two cylinder mechanisms are provided, and twofirst holding sections 51 (61) are provided corresponding to these inthe above-mentioned embodiments, the number of cylinder mechanisms andfirst holding sections 51 (61) are not particularly limited.

1. An electrical conductor aligning method of aligning a plurality ofelectrical conductors in an annular shape while overlapping in acircumferential direction, the method comprising: an arranging step ofarranging the plurality of electrical conductors in an annular shape atan interval so as not to overlap in a circumferential direction, byholding one leg of each of the electrical conductors with a plurality ofholding sections; and an aligning step of aligning the plurality ofelectrical conductors in an annular shape while overlapping in thecircumferential direction, by causing the plurality of electricalconductors arranged in the annular shape to move to an inner side in theradial direction while holding one leg of each of the electricalconductors so as not cause interference between adjacent holdingsections.
 2. The electrical conductor aligning method according to claim1, wherein the plurality of holding sections is arranged so that thepositions of adjacent holding sections are alternately displaced in thecentral axis direction of a ring formed by the plurality of holdingsections thereby holding the one leg of each of the electricalconductors so as to be alternately displaced in the central axisdirection of the ring.
 3. The electrical conductor aligning methodaccording to claim 1, wherein the plurality of holding sections hold aleg of a coil element by slidably sandwiching a leading end side of eachhook part and a projecting part of the plurality of holding sectionsinbetween, so that the hook part is pushed to spread outwards.
 4. Theelectrical conductor aligning method according to claim 1, wherein theplurality of holding sections move along a slide rail that extends inthe radial direction.
 5. The electrical conductor aligning methodaccording to claim 1, wherein the plurality of electrical conductors iscomprised of a first electrical conductor and a second electricalconductor of a different shape from the first electrical conductor, andwherein the aligning step is performed by respectively holding one legof the first electrical conductor and one leg of the second electricalconductor utilizing the plurality of holding sections that hold theelectrical conductors.
 6. The electrical conductor aligning methodaccording to claim 1, wherein the arranging step is performed byinserting legs of the plurality of electrical conductors into the spaceensured between the legs and the holding sections to enable insertion ofthe legs thereto, and then narrowing the space thereby gripping the legsby the holding sections inbetween.
 7. The electrical conductor aligningmethod according to claim 1, wherein the aligning step is performed bypushing the plurality of electrical conductors to an interior of aconcave part of the holding sections after the holding sections hold theplurality of electrical conductors.